JAC S2 (Chassis). Instruction — part 3

Clutch

Clutch

21

Clutch

I. Overview

(I) Structure Summary

Architectural Overview

Clutch assembly is located between the engine and gearbox, the clutch pressure plate is fixed to the

rear plane of the flywheel by a bolt assembly. Clutch disc and gearbox are connected by a spline input
shaft which can slide axially, and transmit torque to the surrounding. During driving, according to the
depressing or releasing the clutch pedal to temporary separate and gradually engage the engine and
gearbox to cut off or pass the input power from the engine to the transmission.

Clutch system includes the following components:

• Active parts: clutch pressure plate assembly clutch pressure plate assembly is bolted to the flywheel.
• Follower: Clutch disc Clutch disc and gearbox are connected by a spline input shaft. Active parts and
the follower are kept in contact by spring pressure. This pressure is exerted by a diaphragm spring
pressure inside plate assembly.
• Operating parts: clutch control system includes a clutch pedal, master cylinder, tubing, cylinder,
separation fork and bearing, when depress the clutch pedal, through hydraulic pressure, master cylinder
pushes cylinder, separation fork, through bearing pushes diaphragm spring separation claw, release the
pressure plate, to disengage the clutch

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Clutch control system

1.

Clutch pedal assembly

2. Clutch hard pipe assembly -I
3. Clutch bracket -I

4. Clutch master cylinder and the inlet pipe assembly
5. Clutch cylinder assembly

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Structure chart of clutch pressure plate and driven disc

1. Clutch cover and pressure plate assembly
2. Clutch driven disc
3. Hexagon head bolt and spring washer assemblies

(II) Maintenance parameters

Maintenance parameters

No

Item

Parameters

1

clutch pedal free travel

6~20mm

grease

No

Item

Grease model

1

cylinder

kingpin

Kunlun II low temperature grease

(III) Torque parameters

No

Item

Torque（N·m）

Remark

1 clutch pedal fixing bolt

20~28

2 clutch pedal fixing nut

20~28

3 oil pipe mounting bracket

8~12

4 exhaust bolt

20~28

5 clutch pressure plate mounting bolts

20~28

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(IV) Maintenance precaution

Precautions
• The recommended clutch hydraulic oil is brake fluid "DOT 4".
• Do not reuse drained clutch hydraulic oil.
• Be careful not to spill clutch hydraulic oil on the body paint.
• Do not use gasoline or kerosene and other mineral oils; otherwise it will corrode the rubber parts of the
hydraulic system.
• Do not disassemble master cylinder and hydraulic release bearing.
△ WARNING Use vacuum cleaner to clean clutch plate, but not with compressed air.
Inspection Points

△ CAUTION Do not use a vacuum pump or any other type of evacuation power plant to operate the
system. Check the fluid level of the clutch hydraulic oil; make sure that the level is normal. Do not let
the clutch hydraulic oil fall on the body paint or other components. If the clutch hydraulic oil spilled on
the body paint or other parts, immediately wipe clean with a dry cloth.

(V) Special tools

No

Tool

Tool Dimensions

Description

1

Flywheel stopper

Fixed flywheel

II. Fault diagnosis

(I) Common fault diagnosis

Clutch assembly and clutch control system performance diagnosis should be performed by an

experienced driver or a skilled vehicle maintenance technician.

The following (failure) diagnosis involves common problems and possible causes. After appropriate

diagnosis, make adjustments according to the respective solutions in service instruction diagnostic table and
corresponding to the appropriate section in each of the specific program, replace the parts as required.

During vehicle maintenance, clutch pressure plate and clutch disc cannot be repaired, if any one of

them is broken, replace the entire assembly.

If the clutch driven plate rivets polished or clutch disc polluted by oil or grease dirt, then it cannot be

used. If you need to replace a part, use well qualified new parts to replace it. The table below will help
diagnose the causes under the following conditions leads to emergence of a clutch system: not separation,
separation incomplete; the engagement incomplete, slip, noise and jitter

The number in the diagnosis table does not mean order of examination, there is no precedence

relations among the various possible causes.

(II) Diagnosis table

No Failure

performance

Failure cause analysis

Solution

Remark

clutch lever deformation

replace the deformation part

Refers to

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1

Unable to
separate

diaphragm spring deformation

replace the deformation part

clutch
unable to
separate
flowchart

diaphragm spring support ring
broken

replace the broken part

clutch pedal spring break and fatigue replace the worn and broken part

clutch driven disc and flywheel or
clutch pressure plate or bonding

adjusting clutch system

2

Unable to
incomplete
separate

clutch driven disc deformation
when it turns it will swing

replace deformation, wear,
cracks and exceeding standard
size parts

Refers to the
unable to
incomplete
separate
flowchart

clutch driven disc broken

Replace clutch driven disc

clutch driven disc input does not
match with the gearbox shaft input,
or the input surface is worn

spline clutch disc not work well
with the gearbox input shaft
spline, to replace the clutch disc,
if any necessary, replace the
gearbox input shaft

clutch partly adhesive flywheel or
clutch pressure plate or bite

replace the non-qualified parts

flywheel / clutch pressure plate /
clutch disc exceeds standard size

replace the non-qualified parts

clutch pedal and the clutch control
system drawing mechanical failure
or improper adjustment

adjust clutch system, remove
unnecessary gap, eliminate
mechanical failure and reinstall
improper assembly parts

3

Unable to
incomplete
connect

clutch driven disc stained by oil or
grease dirt

Clean up the oil or grease dirt

Refers to the
unable to
incomplete
connect
flowchart

clutch driven disc broken

replace the deformation worn and
broken part

no clutch pedal free travel

properly adjust clutch pedal free

travel 程

diaphragm spring / clutch pressure
plate / clutch lever/ Clutch disc
splines deformed or damaged

replace clutch disc or clutch
assembly problem

Clutch pedal and the clutch control
system drawing mechanical failure
or improper adjustment

adjust clutch system, remove
unnecessary gap, eliminate
mechanical failure and reinstall
improper assembly parts

clutch plate wear

replace driven disc

Refers to

Clutch

Clutch

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4 Slipping

Clutch contaminated by oil or grease clean the grease or replace driven

disc

clutch
slippage
flowchart

Clutch engagement is not complete The same with "incomplete

separation" and "engaging
incomplete" solutions

Flywheel / clutch pressure plate /
clutch plate thickness exceeds a
predetermined size

Replace non-qualified parts

improper driving leads to clutch
housing over heating

Turn off the engine, cool the
temperature in the clutch(if
overheated) and operate further
diagnosis

Improper installation

reinstall

5

noise

Improper clutch driven disc

Install requested clutch driven
disc

Refers to
clutch noise
flowchart

Improper balancing

If any part has improper
balancing, replace the whole
cutch

Clutch thrust bearing failure

adjusting clutch brush
and reinstall improper
assembly of parts

Clutch disc torsion damping spring
damaged

replace deformation, wear and
tear parts

6

Jitter

Clutch damper spring does not meet
the specifications

Replace the driven disc

Clutch driven disc does not meet
specifications

Replace the driven disc

Clutch pollution by oil or grease

Replace the driven disc

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(III) Fault diagnosis flowchart

Clutch unable to separate flowchart

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Unable to incomplete separate flowchart

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Unable to complete connect flow chart

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Clutch slippage flowchart

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Clutch noise flowchart

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III Clutch pedal

(I) Remove

1. Open the engine hatch,
2. Disconnect the negative battery cable,
3. Drain the clutch hydraulic oil refers to clutch hydraulic oil,
4. Remove the lower driver's side fender body refers to the lower driver's side fender body
5. Remove the driver's airbag assembly refers to driver's airbag assembly
6. Remove the steering assembly refers to steering assembly See
7. Remove the steering column on the shell package; under the steering column cladding refers to the
steering column cladding
8. Remove the clock spring refers to clock spring
9. Remove the combination switch refers to combination Switch
10. Removing burglar alarm induction coil refers to induction coil
11. Remove ignition lock assembly refers to the ignition lock assembly
12. Remove the steering column assembly refers to the steering column assembly
13. Removing the clutch pedal

1). Disconnect clutch wire harness connector.

2). Remove the clamp connected clutch pedal and
the clutch master cylinder, disassembly latch,
disengage the connection of clutch pedal and
clutch master cylinder.

3). Remove the two bolts connecting upper part
of clutch pedal and body.

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4). Remove the two fixing nuts connecting clutch
pedal and the lower part of the body.

5). Remove the clutch pedal.

(II) Check

1. Check the clutch pedal after demolition

1) Check if the clutch pedal is distorted, damaged,
cracked or appears weld.

2). If occurs, please replace the clutch pedal assembly

(III) Installation

1. Install the clutch pedal

1). Place the clutch pedal to the mounting position.

2). Install two nuts connecting he clutch pedal and
the lower part of the body.

Tightening torque

20~28N·m

3). Install two bolts connecting the clutch pedal and
the upper portion of the body. Tightening torque 20 ~
28N • m

4). Install lock pin, install the clamp connecting
clutch pedal and the clutch master cylinder.
△ Note Before installation, coat low grease Kunlun II

to the outer surface of the front pin。

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5) Connect clutch harness connector.

2. Adjust the clutch pedal free travel
3. Install the steering column assembly
4. Install the ignition lock assembly
5. Install anti-theft induction coil
6. Install the combination switch
7. Install the clock spring
8. Install the lower steering column cladding, under
the steering column cladding
9. Install the steering wheel assembly
10. Install the driver's airbag assembly
11. Install the lower driver side fender body
12. Fill the clutch hydraulic oil
13. Connect the negative battery cable
14. Close the engine hatch

IV. Clutch pedal stroke

1. Measure clutch pedal free travel

1). gently press the clutch pedal by hand to determine
when the pedal drop resistance, measure clutch pedal
free travel by scale.

Free travel: 6 ~ 20mm
△ Attention if the clutch pedal free travel is not in
specified region, then it must be the clutch hydraulic
circuit with air or clutch master cylinder is faulty.
Exhaust the systems, check the master cylinder or
dismantle the clutch.

2. Adjust the clutch pedal travel

1) Loosen the lock nut and turn the bolt, adjust the
clutch pedal travel. After adjusting, tighten the
lock nut.
Tightening torque 20 ~ 28N • m
△ Attention when adjust the height of the clutch
pedal, do not push the lever to the clutch master
cylinder.

V. Clutch hydraulic oil

1. Drain the clutch hydraulic oil

1) Open the brake fluid filler cap.

2) Place drip pan.

3). Empty brake fluid

4) Install the brake fluid filler cap.

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△ Note cover the painted surface with a rag or cloth to
prevent adhesive of brake fluid.

2. Fill clutch hydraulic oil

1). Depress the brake pedal several times until the
complete elimination of the vacuum booster pressure.

2) Open the brake fluid filler cap.

3) Fill brake fluid.
△ NOTE Open the front tank cover, clean, only allowed to
store brake fluid in a sealed container.

3. Clutch system exhaust

△ Note after installing the clutch line, clutch master
cylinders, clutch assembly and clutch cylinder, if found
pedal weak, exhaust the system

1) Loosen the clutch working cylinder exhaust bolts。

2) Slowly depress the clutch pedal until the air is
completely discharged.

3).) fully depress the pedal and hold, tighten the exhaust
bolts.

4) Supply clutch hydraulic system with hydraulic oil.
△ Note always keep the liquid level in the tank between
MIN and MAX

5) Repeat steps 1-4 until clutch hydraulic oil discharged
from the system is clean and with no air bubbles.

4. Check whether the clutch is working properly

1) Start the engine; depress the clutch pedal, carefully
hang in reverse gear after 2s. If there is big noise during
gear selection, fully depress the clutch pedal five times to
exhaust the system.

2) After waiting for about 30s and then check the work
situation of the clutch. If there is still big noise, repeat the
above step

VI. Clutch switch assembly

(I) Remove

1. Open the engine hatch
2. Disconnect the negative battery cable

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3. Remove the lower driver's side fender body refers to the lower driver's side fender body
4. Remove the clutch switch assembly

1). Disconnect the clutch switch harness connector.

2). Remove the buckle connecting the clutch pedal with
clutch switch harness, disconnect the clutch switch and
pedal.

3) Removing the clutch switch fixed nut.

4) Remove the clutch switch.

(II) Installation

1. Install the clutch switch assembly

1). Place clutch switch assembly to the mounting
position.

2) Tighten the clutch switch fixing nut.

3) Install the knuckle connecting clutch switch and
clutch pedal

4) Connect the clutch switch harness connector.

2. Install the lower driver side fender body
3. Connect the negative battery cable
4. Close the engine hatch

VII Clutch master cylinders and inlet pipe assembly

(I) Remove

1. Open the engine hatch